Liquid delivery cap devices, systems, and methods

ABSTRACT

A liquid delivery system cap device is provided. In some embodiments, an example cap device includes a body defining a cavity configured to receive at least a portion of a liquid delivery device, a first sensor configured to output a first sensor signal indicative of a plunger of the liquid delivery device, a second sensor configured to output a second sensor signal indicative of a position, and a processor configured to detect a plunger of the liquid delivery device based on a variation in the sensor signal of the first sensor and to determine a corresponding position based on a sensor signal output by the second sensor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Application Ser. No.62/599,964, filed on Dec. 18, 2017. The disclosure of the priorapplication is considered part of the disclosure of this application,and is incorporated in its entirety into this application.

TECHNICAL FIELD

This document describes devices, systems, and methods related to capdevices of a liquid delivery device, for example, cap devices configuredto detect a plunger of the liquid delivery device.

BACKGROUND

Liquid delivery systems are commonly used to deliver a measured quantityof a drug to a patient. For example, pen-injector delivery devices havebeen used to deliver a measured quantity of a drug, and include adelivery end that is capped for storage between uses and a plungermovable within a reservoir to dispense a measured dose. A cap device mayprotect the delivery end from damage during storage and may be used todisplay information to a user, such as a duration since the cap was lastremoved during a previous use of the injection device or informationabout the contents of the delivery device.

SUMMARY

Some embodiments described herein include cap devices, systems, andmethods configured to detect a condition of a liquid delivery device andoutput dosage information based on the detected condition. For example,a liquid delivery system may include a liquid delivery device having areservoir and a movable plunger to force liquid from the reservoir, anda cap device configured to cover at least a delivery end of the liquiddelivery device. The cap device includes one or more sensors configuredto detect a condition of the liquid delivery device, such as a positionof the plunger. The plunger position can be used to determine the liquidvolume within the reservoir, dosage information (e.g. the volume of apreviously delivered dose), and/or other information related to theliquid delivery device and its operation.

Some example cap devices optionally include a body and a sensor carriagemovably located within the body. The sensor carriage may include one ormore sensors that output sensor signals. The sensor signals may varybased on a feature of the liquid delivery sensor encountered by the oneor more sensors, such as a plunger or liquid within the reservoir. Insome embodiments, the sensor carriage may be movable between first andsecond positions without user operation, or movable by positioning thecap device on the liquid delivery device without additional useroperation.

Some example cap devices may facilitate accurate and repeatabledetection of the plunger position of the liquid delivery device, and inturn, the volume of a previously delivered dose or the volume remainingin the reservoir, for example. Alternatively or additionally, someembodiments facilitate accurate and repeatable measurement by reducingmanual manipulation during detection. For example, the sensor carriagemay move between first and second positions while the liquid deliverydevice is in a fixed position relative to a body of the cap device, andwithout additional manual operation by a user beyond the operation ofengaging the liquid delivery device with the cap device.

In some embodiments, the sensor carriage may be pushed inward into acavity of the cap device by engagement of the liquid delivery devicewith the cap device. The sensor carriage may optionally be movable withthe liquid delivery device until the cap device is retained on theliquid delivery device, at which point the sensor carriage maysubsequently be released. One or more sensors of on the sensor carriagemay be configured to scan the liquid delivery device while the sensorcarriage travels from a first position to a second position. Subsequentdisengagement or removal of the liquid delivery device from the capdevice may reset the cap device to allow subsequent engagement with theliquid delivery device. Accordingly, in some example embodiments, thecap device may be configured to repeatedly and reliably scan a liquiddelivery to detect its plunger, and/or to evaluate characteristics ofthe liquid delivery device and its use.

In some optional embodiments, the cap device includes one or moresensors configured to output sensor signals indicative of a feature ofthe liquid delivery device, and one or more positions sensors configuredto output sensor signals related to position. For example, the capdevice may include first and second optical sensors configured to outputsensor signals indicative of a plunger of the liquid delivery device,and a linear potentiometer configured to output sensor signals that canbe used to determine a corresponding position of the plunger. In variousexample embodiments, the cap device may optionally include one or morecolor sensors, infrared sensors, image sensors, etc., and/or one or moreof a rotary encoder, linear encoder, membrane potentiometer, magnetpotentiometer, etc.

Particular embodiments described herein include a liquid delivery systemcap device, the cap device comprising a body defining a cavityconfigured to receive at least a portion of a liquid delivery device;and a sensor carriage movable within the cavity and including a firstsensor. The sensor carriage may be movable between a first position anda second position relative to the cavity while the liquid deliverydevice is in a fixed positon relative to the cavity.

In some implementations, the system can optionally include one or moreof the following features. The cavity may be defined by a front wall andone or more side walls of the body, and the body may define an openingto the cavity. In the first position the sensor carriage may be locatedproximate the front wall. In the second position the sensor carriage maybe located proximate the opening. The device may further comprise aspring, the spring biased to move the sensor carriage from the firstposition to the second position. The first sensor may be configured tooutput a sensor signal indicative of a physical feature of the liquiddelivery device. The first sensor may be configured to output a sensorsignal indicative of a plunger of the liquid delivery device while thesensor carriage moves between the first position and the secondposition. The sensor carriage may comprise a first transmissive sensor.The sensor carriage may comprise a first reflective sensor. The sensorcarriage may comprise an optical sensor having a first optical emitteraligned with a first optical receiver. The first sensor may comprise anoptical path between the first optical emitter and the first opticalreceiver, and the optical path may be perpendicular to a longitudinalaxis of the cavity of the cap device. The optical path may not intersecta central longitudinal axis of the cavity of the cap device. The sensorcarriage may comprise a second optical sensor having a second opticalemitter aligned with a second optical receiver. The first opticalemitter may not be aligned with the second optical receiver, and thesecond optical emitter may not be aligned with the first opticalreceiver. The device may further comprise a position sensor. The devicemay further comprise a processor configured to detect a plunger of theliquid delivery device based on a variation in the sensor signal of thefirst sensor, and to determine a corresponding position based on asensor signal output by the position sensor. The position sensor maycomprise a linear potentiometer, the linear potentiometer may include aresistive element and a wiper movable along the resistive element. Thewiper may be located on the sensor carriage. An output of the linearpotentiometer may be indicative of a position of the sensor carriage.The position sensor may comprise a linear encoder, the linear encodermay include a codestrip and an encoder movable along the codestrip. Theposition sensor may comprise a rotary encoder, the rotary encoder mayinclude a codewheel and an encoder.

Particular embodiments described herein include a liquid deliverysystem, comprising a liquid delivery device including a reservoir, aliquid within the reservoir, and a plunger movable within the reservoirto dispense liquid from the reservoir; and a cap device including a bodydefining a cavity configured to receive at least a portion of a liquiddelivery device, a sensor carriage movable within the cavity andincluding one or more sensors configured to output a sensor signalindicative of a physical feature of the liquid delivery device, and aposition sensor. The sensor carriage may be movable between a firstposition and a second position relative to the cavity while the liquiddelivery device is in a fixed positon relative to the cavity.

In some implementations, the system can optionally include one or moreof the following features. The cap device may comprise a processorconfigured to detect a plunger of the liquid delivery device based on avariation in the sensor signal of the first sensor, and to determine acorresponding position based on a sensor signal of the position sensor.The processor may be located in the cap device. The one or more sensorsmay be located on the sensor carriage may comprise first and secondoptical sensors, the first optical sensor having a first optical emitteraligned with a first optical receiver, and the second optical sensorhaving a second optical emitter aligned with a second optical receiver.The first optical sensor may comprise an optical path between the firstoptical emitter and the first optical receiver, and the optical path maybe perpendicular to a central longitudinal axis of the cavity of the capdevice. The first optical path may not intersect a central longitudinalaxis of the cavity of the cap device.

Particular embodiments described herein include a method of evaluatingthe condition of a liquid delivery device, comprising receiving at leasta portion of a liquid delivery device within a cavity of a cap device;releasing a sensor carriage including one or more sensors to move thesensor carriage from a first position to a second position while theliquid delivery device remains in a fixed position within the cavity;evaluating an output of the one or more sensors indicative of thepresence of a feature of the liquid delivery device.

In some implementations, the system can optionally include one or moreof the following features. The method may further comprise evaluating bya processor within the cap device an output of a position sensor toevaluate a position of the feature of the liquid delivery device. Thefeature of the liquid delivery device may be a plunger. The one or moresensors may comprise first and second optical sensors, and the positionsensor may comprises a linear potentiometer including a resistiveelement and a wiper. The wiper may be located on the sensor carriage.

Particular embodiments described herein include a liquid delivery systemcap device, comprising a body defining a cavity configured to receive aliquid delivery device; and means for moving one or more plunger sensorswith the cavity of the body.

In some implementations, the system can optionally include one or moreof the following features. The cap device may further comprise means fordetecting a position of the one or more plunger sensors.

Particular embodiments described herein include a liquid delivery systemcap device, the cap device comprising a body defining a cavityconfigured to receive at least a portion of a liquid delivery device; afirst sensor configured to output a first sensor signal indicative of aplunger of the liquid delivery device; a second sensor configured tooutput a second sensor signal indicative of a position; and a processorconfigured to detect a plunger of the liquid delivery device based on avariation in the sensor signal of the first sensor, and to determine acorresponding position based on a sensor signal output by the secondsensor. The second sensor may comprise a linear encoder including a codestrip and an encoder.

In some implementations, the system can optionally include one or moreof the following features. The linear encoder may be a reflective linearencoder. The linear encoder may be a transmissive linear encoder. Theencoder may be located on a sensor carriage movable within the cavity ofthe body between a first position and a second position. The firstsensor may be fixed relative to the body. The first sensor may belocated on the sensor carriage and movable between the first positionand the second position. The cap device may include a first springbiased to move the sensor carriage between the first position and thesecond position. The sensor carriage may comprise a second spring infrictional engagement with the body while the sensor carriage movesbetween the first position and the second position. The encoder may beseparated from the code strip by a space when the sensor carriage ismovable between the first position and the second position.

Particular embodiments described herein include a liquid delivery systemcap device, the cap device comprising a body defining a cavityconfigured to receive at least a portion of a liquid delivery device; afirst sensor configured to output a first sensor signal indicative of aplunger of the liquid delivery device; a second sensor configured tooutput a second sensor signal indicative of a position; and a processorconfigured to detect a plunger of the liquid delivery device based on avariation in the sensor signal of the first sensor, and to determine acorresponding position based on a sensor signal output by the secondsensor. The second sensor may comprise a rotary encoder including acodewheel and an encoder.

In some implementations, the system can optionally include one or moreof the following features. The cap device may comprise a track and acarriage movable between a first position and a second position alongthe track, and the carriage may be configured to receive a delivery endof a liquid delivery device. The track may include a helical slot, andthe track may be rotatable by movement of the carriage between the firstposition and a second position along the helical slot. Rotation of thetrack may cause rotation of the codewheel. The cap device may comprise agear train, and rotation of the track may be translated to the codewheelvia the gear train. The carriage may not include a sensor or sensorcomponent. The first sensor may be fixedly positioned relative to thebody of the cap device. The first sensor may be located on the carriagemovable between a first position and a second position.

Particular embodiments described herein include a method of evaluatingthe condition of a liquid delivery device, comprising receiving at leasta portion of a liquid delivery device within a cavity of a cap device;generating by a first sensor a first sensor signal indicative of afeature of a liquid delivery device; generating by a second sensor asecond sensor signal output indicative of a position associated with thefirst sensor signal output; evaluating the first sensor signal outputand the sensor signal output to determine a position of the feature ofthe liquid delivery device.

In some implementations, the system can optionally include one or moreof the following features. The second sensor may comprise a linearencoder including a code strip and an encoder, and generating the secondsensor signal output comprises moving the encoder along the code strip.The second sensor may comprise a rotary encoder including a code wheeland an encoder, and generating the second sensor signal output comprisesrelative rotation between the codewheel and the encoder. The feature maybe a plunger of the liquid delivery device. The method may furthercomprise displaying an output related to the position of the plunger.The output may be the volume of a previous dose delivered from theliquid delivery device.

The devices, system, and techniques described herein may provide one ormore of the following advantages. First, some embodiments describeherein include a cap device that can facilitate accurate and repeatablemeasurements related to a liquid delivery device. For example, a sensorcarriage carrying a sensor component (and/or that is movable withlimited or no manual user operation) can promote a consistent travelvelocity and/or acceleration that facilitates consistent and predictablesensor signals. User influence on the dynamics of the sensor carriagemay be reduced, and manufacturing design tolerances that may result inclearance play or other inadvertent movement of the sensor carriageduring operation of the sensor carriage can be reduced.

Second, some embodiments described herein may facilitate accurate andrepeatable measurements related to the liquid delivery device by using acombination of sensor types. In some embodiments, the cap deviceincludes one or more optical sensors together with a position sensor,such as a linear potentiometer, optical encoder, rotary encoder,magnetic potentiometer, membrane potentiometer, load cell, etc., forexample. The combination of such sensor types facilitates accurateevaluation of relative positions of various features of liquid deliverydevice and/or a change in position of various features during subsequentscans of the liquid delivery device.

Third, the cap device may promote efficient and cost-effectivemanufacturing and assembly processes by including relatively fewsensors. In some embodiments, the cap device includes one or two liquiddelivery device sensors (e.g. plunger sensors), such as one or twooptical sensors, and a position sensor, such as a linear potentiometer,optical encoder, rotary encoder, magnetic potentiometer, membranepotentiometer, etc. Such configurations thus include relatively fewsensors, and reduce the number of assembly and/or calibration steps thatotherwise may be appropriate to assemble many sensors into the capdevice.

Fourth, various embodiments described herein may include a cap devicecompatible with a variety of liquid delivery device types. For example,the cap device may facilitate accurate and repeatable measurements evenwhen used with distinct liquid delivery device types that may havevarying shapes, sizes, and features that interact differently with thesensors and other features of the cap device. One or more opticalsensors of the sensor carriage may be oriented to obtain predeterminedlines of sight that promote reliable plunger detection for a variety ofdifferent liquid delivery device types. For example, optical sensors maybe arranged so that at least one optical sensor is positioned to detectthe plunger, even if another optical sensor is obstructed by a featureof the liquid delivery device at a particular instance.

Fifth, some cap devices described herein improve the user experience ofa liquid delivery system by automating some actions related to dosemeasurement and management. For example, the cap device may deliveroutput that informs a user of a previously delivered dose of the liquid,a duration since the previous dose, a number of doses remaining, avolume of liquid remaining, an expected life remaining of the liquiddelivery device.

Sixth, in some optional embodiments, cap devices described herein mayimprove the user experience of a liquid delivery system by facilitatingsemi-automatic or automatic operation. For example, little or no manualoperation may be required beyond engaging the cap device with the liquiddelivery device. In some optional embodiments including a movable sensorcarriage, the sensor carriage may be brought into a first position byengagement of the cap device onto the liquid delivery device, and thesensor carriage may be automatically released such that the sensorcarriage can move from the first position to the second position whileoperating to scan the liquid delivery device.

Seventh, some embodiments described herein facilitate a durable capdevice that can operate over an extended period of time and/or that maybe used with many liquid delivery devices. For example, a single capdevice may be reusable with many disposable liquid delivery devices. Thesensors of the cap device, such as one or more plunger sensors andposition sensors, such as one or more optical sensors, load sensors,linear potentiometers, optical encoders, rotary encoders, magneticpotentiometers, membrane potentiometers etc., may be configured to haveconsistent and/or predictable output over the operational life of thecap device.

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features andadvantages will be apparent from the description and drawings, and fromthe claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is an exploded perspective view of an example liquid deliverysystem including a cap device.

FIG. 2 is a cross-sectional view of the example liquid delivery systemof FIG. 1.

FIG. 3 is a partial cross-sectional view of the example liquid deliverysystem of FIG. 1, showing a sensor carriage including one or more sensorcomponents.

FIG. 4 is a perspective view of the sensor carriage of the exampleliquid delivery system of FIG. 1.

FIG. 5A is an end view of the cap device of the example liquid deliverysystem shown in FIG. 1.

FIG. 5B is a perspective view of the liquid delivery system of FIG. 1.

FIG. 5C is a partial cross-sectional view of the example liquid deliverysystem of FIG. 1, showing movement of the sensor carriage as the liquiddelivery device is received in the cavity of the cap device.

FIGS. 6A-6C show a sensor carriage of the example liquid delivery systemof FIG. 1 in a first position, intermediate position, and secondposition.

FIG. 7A is a cross-sectional view of the example liquid delivery systemof FIG. 1 showing engagement features of the sensor carriage in anextended position.

FIG. 7B is a cross-sectional view of the example liquid delivery systemof FIG. 1 showing engagement features of the sensor carriage in aretracted position.

FIG. 8 is a partial cross-sectional view of the example liquid deliverysystem of FIG. 1, including a rotation feature of the cap device.

FIG. 9A is a partial perspective view of an example liquid deliverydevice.

FIG. 9B is a cross-sectional view of the example liquid delivery deviceof FIG. 9A.

FIGS. 10A and 10B show an example sensor carriage including arms in anextended or engaged configuration.

FIGS. 10C and 10D show an example sensor carriage including arms in aretracted or disengaged configuration.

FIGS. 11A-11F show an example sensor carriage in multiple positionswithin a cap device.

FIG. 12 is a cross-sectional view of an example liquid delivery deviceincluding a linear encoder.

FIG. 13 is a cross-sectional view of an example liquid delivery deviceincluding a rotary encoder.

FIG. 14 is a flow diagram of an example method of evaluating thecondition of a liquid delivery device.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring to FIGS. 1 and 2, an example liquid delivery system 10 isshown that can be used to store and deliver a liquid, and output dosageinformation to a user. Liquid delivery system 10 includes cap device 100and liquid delivery device 200. Liquid delivery device 200 includes areservoir 201, delivery end 202, and a plunger 205 that can be operatedto deliver a dose of the liquid within reservoir 201 through deliveryend 202. Cap device 100 is positionable over delivery end 202 of liquiddelivery device 200 for storage of liquid delivery device 200 betweenuses. In an example embodiment, cap device 100 includes one or moresensors configured to detect a condition of liquid delivery device 200,such as a position of its plunger, and one or more output devices, suchas a display, communication system, etc., configured to outputinformation related to the condition of liquid delivery device 200.

Liquid delivery device 200 may be configured to deliver a measured doseof a liquid to a subject for the treatment of a medical condition. Forexample, liquid delivery device 200 may be a pen injector for deliveringa liquid, such as insulin, to manage diabetes. In an example embodiment,delivery end 202 of liquid delivery device 200 includes a septum 203 andan injection needle 204. A desired dosage may be measured by operationof dial 206 (e.g. by manually rotating dial 206), and delivered byadvancing plunger 205. Advancement of plunger 205 via rod 214 pushes themeasured dosage of liquid from reservoir 201, through delivery end 202,and into the subject. In an example embodiment, advancement of plunger205 a particular distance causes a corresponding volume of liquid to bedispensed from liquid delivery device 200.

Cap device 100 includes a body 110 that defines a cavity 111 configuredto receive at least a portion of liquid delivery device 200, such as atleast a portion of delivery end 202 and/or reservoir 201. Cap device 100is positionable over delivery end 202 and may retain liquid deliverydevice 200 (e.g. between periods of use). Cap device 100 may protectdelivery end 202 from damage or contaminants of the externalenvironment, and contain injection needle 204. Liquid delivery device200 may be removed from cavity 111 of cap device 100 before each use,and subsequently engaged with cap device 100 after a dose has beendelivered. Cap device 100 may thus be removed from and replaced ontoliquid delivery device 200 over multiple uses. After the contents of aparticular liquid delivery device 200 has been exhausted, the liquiddelivery device 200 may be discarded, and cap device 100 used with a newliquid delivery device. In some example embodiments, liquid deliverydevice 200 is disposable when its usable contents are exhausted, and capdevice 100 may be reusable with multiple liquid delivery devices 200. Inother example embodiments, cap device 100 may be associated with aparticular liquid delivery device 200, and both the cap device 100 andthe liquid delivery device 200 may be disposed when the contents ofreservoir 201 are exhausted.

Cap device 100 may include one or more sensors configured to detect acondition of liquid delivery device 200. In an example embodiment, capdevice 100 includes sensors that output sensor signals that may beevaluated to detect plunger 205, a position of plunger 205, a change inposition of plunger 205 between successive engagements with cap device100 (e.g. a change in position after delivery of a dose), and/or otherconditions of liquid delivery device 200. The position of plunger 205,and/or the change in the position of plunger 205, may be used to monitora volume of a dose delivered by liquid delivery device 200, a remainingtotal volume of liquid within reservoir 201, a remaining number of doseswithin reservoir 201, a remaining duration until reservoir 201 isemptied, and/or other information related to liquid delivery device 200.

Cap device 100 may include various components that facilitatecalculation, display, storage, and/or communication of sensor signalsthat may be output by the one or more sensors. In an example embodiment,cap device 100 includes a display 121, user inputs 122, communicationdevice 123, memory 124, processor 125, speaker 126, and circuit board127. One or more components may be in electrical communication with oneor more other components via circuit board 127, and processor 125 may beconfigured with logic to control operation of one or more of display121, user inputs 122, communication device 123, memory 124, and speaker126, and to process sensor signals received from one or more sensors ofcap device 100.

Display 121 provides a visual output to a user related to a condition ofcap device 100 and/or liquid delivery device 200. Display 121 may be anLED or LCD display, for example. In some embodiments, display 121 mayprovide a visual indication related to a volume of a dose delivered byliquid delivery device 200, a remaining total volume of liquid withinreservoir 201, a remaining number of doses within reservoir 201, aremaining duration until reservoir 201 is emptied, a time of theprevious dose (e.g. a time the cap device 100 was replaced on liquiddelivery device 200), an elapsed time since the last dose (e.g. anelapsed time since cap device 100 was replaced on liquid delivery device200), and/or other information related to liquid delivery device 200.

Alternatively or additionally, cap device 100 may include audio and/orvibratory alerts related to a condition of cap device 100 and/or liquiddelivery device 200. Processor 125 may control audio output of speaker126 to output an audible alert, or vibrator 128 to output a vibratoryalert, which may be perceived as an indication of a volume of a dosedelivered by liquid delivery device 200, a remaining total volume ofliquid within reservoir 201, a remaining number of doses withinreservoir 201, a remaining duration until reservoir 201 is emptied, atime of the previous dose (e.g. a time the cap device 100 was replacedonto liquid delivery device 200), an elapsed time since the last dose(e.g. an elapsed time since cap device 100 was replaced onto liquiddelivery device 200), and/or other information related to liquiddelivery device 200. Alternatively or additionally, vibrator 128 maydeliver vibrations to liquid delivery device 200. Vibrator 128 may beactivated to facilitate mixing of the contents of liquid delivery device200 and/or to reduce the formation or buildup of precipitates (e.g. onthe leading surface of plunger and/or surfaces of reservoir 201).

Cap device 100 optionally includes one or more user inputs 122 thatfacilitate user interaction with cap device 100. In an exampleembodiment, user inputs 122 include first and second buttons that may beoperated to control cap device 100. For example, user inputs 122 may beoperated by a user to activate cap device 100 and/or select informationto be displayed by display 121. Alternatively or additionally, userinputs 122 may be operated to reset settings and/or memory 124 of capdevice 100, such as when cap device 100 is engaged with a new liquiddelivery device 200. In some example embodiments, cap device 100 doesnot include user-inputs 123, such as buttons. Cap device 100 that doesnot include buttons or other user inputs may promote the perception of afully automated cap device 100 and/or improve user operability.

Cap device 100 may communicate with one or more other components of aliquid delivery system to deliver and/or receive information related toa condition of cap device 100 and/or liquid delivery device 200. Forexample, cap device 100 includes a communication device 123 configuredto communicate with one or more components remote from cap device 100.Communication device 123 may include a wireless communication printedcircuit assembly configured for wireless communication, such as viashort-wavelength UHF radio frequency, RF communication, WI-FI,BLUETOOTH, ZIGBEE, etc. Alternatively or additionally, communicationdevice 123 may include an electrical port for wired communication withanother electronic device. In various example embodiments, communicationdevice 123 is configured for two-way communication, such as two-waycommunication with a mobile device having software configured to deliverand receive communications with cap device 100. Alternatively, capdevice 100 may be configured for one-way communication, such as only toupload information to the mobile device, or only to receive informationfrom the mobile device.

Communication device 123 may be configured to communicate with anelectronic device configured with diabetes management software. Forexample, communication device 123 may transmit information related toliquid delivery device 200 that may be further processed by theelectronic device. In this way, cap device 100 may facilitate review ofinformation collected by its sensors by a remote user or healthcareprovider, provide alerts related to liquid delivery system 200 by theelectronic device (e.g. related to a scheduled time for an injection, anearly empty liquid delivery device, etc.), and/or facilitate additionalprocessing and analysis of the information collected by cap device 100.

Cap device 100 includes a power source 170. In an example embodiment,power source 170 comprises one or more batteries, such as alkalinebatteries, nickel cadmium batteries, lithium ion batteries, etc. Powersource 170 may be associated with a micro-switch configured to switchcap device between an inactive or low power state to an active oroperational state in which sensors of cap device 100 are active.Alternatively or additionally, a sensor signal from one or more sensorsof cap device 100, such as one or more position sensors, may provide analert to processor 125 to switch cap device to the active or operationalstate.

Still referring to FIG. 1, body 110 of cap device 100 defines cavity 111configured to receive at least a portion of liquid delivery device 200.Body 110 may be configured to house various components of cap device100, such as display 121, user inputs 122, communication device 123,memory 124, processor 125, speaker 126, and circuit board 127. Invarious example embodiments, body 110 is a molded body, such as a moldedplastic. Body 110 may include multiple body portions that are assembledto from body 110, such as a first body portion 110 a and a second bodyportion 110 b that may be joined to define cavity 111 and/or otherspaces to accommodate components of cap device 100. A body 110 thatincludes first and second body portions 110, 110 b may facilitateefficient manufacturing of body 110 and/or efficient assembly with othercomponents of cap device 100. In other example embodiments, the portionof body 110 that defines cavity 111 may be integrally formed as aunitary component (e.g. such that multiple components do not need to bejoined in order to define cavity 111).

Body 110 includes a front wall 112, side walls 113, and an opening 114to cavity 111. Cavity 111 is at least partially defined by front wall112 and side walls 113. Front wall 112 includes a feature configured toreceive delivery end 202 and/or injection needle 204 of liquid deliverydevice 200, such as a receptacle 112 a including plug 112 b (FIG. 2)that at least partially surrounds injection needle 204. Alternatively oradditionally, front wall 112 may include one or more retention featuresthat engage with liquid delivery device 200 and limit relative movementbetween liquid delivery device 200 and body 110 of cap device 100.

In some optional embodiments, cap device 100 includes sensor carriage140 that is movable within body 110 (e.g. movable within cavity 111).Sensor carriage 140 is configured to travel along at least a portion ofliquid delivery device 200 within cavity 111, and cavity 111 is sized toaccommodate the dimensions of liquid delivery device 200 and a path forsensor carriage 140. Sensor carriage 140 facilitates detection ofcharacteristics of liquid delivery device 200 by carrying one or moresensors along liquid delivery device between a first position and asecond position. In an example embodiment, sensor carriage 140 ismovable between the first position and the second position relative tothe cavity while liquid delivery device 200 remains in a fixed positionrelative to the cavity (e.g. the sensor carriage 140 is movable whilethe liquid delivery device 200 is fixedly engaged with cap device 100).

Cap device 100 may include a track 150. Sensor carriage 140 may travelalong track 150, and track 150 may include one or more features thatguide and/or limit the movement of sensor carriage 140. In an exampleembodiment, track 150 includes one or more slots 151 that interact witha complementary feature of sensor carriage140. Slots 151 define a paththat sensor carriage 140 travels along, such as in a longitudinaldirection between a first position proximate front wall 112 and a secondposition closer to opening 114. In some embodiments, slots 151 includekeyed end regions 152 that allow movement of sensor carriage 140 or acomponent of sensor carriage 140 in one or more additional directions,such as rotation of sensor carriage 140, or a component of sensorcarriage 140 (e.g. such that a sensor carried by carriage 140 does notrotated), about the central longitudinal axis (A) of cavity 111.

In some embodiments, track 150 includes one more features configured tointeract with features of liquid delivery device 200. For example,interior surfaces 153 of track 150 may include features that orientand/or retain liquid delivery device 200 within cap device 100. Track150 may at least partially surround reservoir 201 of liquid deliverydevice, and sensor carriage 140 may be movable between track 150 andside walls 113 that define cavity 111 of cap device 110. Thus, in anexample embodiment, track 150 is positioned between liquid deliverydevice 200 and sensor carriage 140 during operation of sensor carriage140.

In some embodiments, track 150 may be integrally formed with body 110 ofcap device 100. For example, track 150 may be integrally formed withbody 110 as a unitary component. Alternatively, track 150 may be formedas a component separate from other components of body 110 andsubsequently assembled with the other components of body 110. Aseparately formed track 150 may facilitate manufacture of track 150(e.g. which may optionally have tighter manufacturing tolerances and/orinclude features otherwise difficult to form within cavity 111 of body110).

Sensor carriage 140 is movable along a longitudinal axis of cap device100 (e.g. a longitudinal axis extending centrally through front wall 112and opening 114) and/or may be rotatable (e.g. a component of sensorcarriage 140 may be rotatable) about the longitudinal axis at particularlocations. When cap device 100 engaged with liquid delivery device 200,sensor carriage 140 may travel along at least a portion of liquiddelivery device 200, such as between delivery end 202 to a positionbeyond plunger 205, for example. In an example embodiment, cap device100 includes a spring 160 configured to move sensor carriage 140 from afirst position to a second position. For example, spring 160 may bemanually compressed as sensor carriage 140 is moved into a firstposition proximate the front wall 112 of body 111. The sensor carriage140 may be moved into the first position when liquid delivery device 200is inserted into cavity 111 (e.g. liquid delivery device 200 may pushsensor carriage into the first position), and sensor carriage 140 may besubsequently released to move to a second position proximate opening 114of body 111 when released (e.g. independent of liquid delivery device200). In various example embodiments, spring 160 is a coil spring.Alternatively or additionally, spring 160 may be an elastic band, wire,elastic component, or other component configured to bias sensor carriage140 towards a particular position.

In various example embodiments, liquid delivery device 200 remains in afixed position relative to cavity 111 and body 110 of cap device 100while sensor carriage 140 travels along liquid delivery device 200.Liquid delivery device 200 is constrained against twisting or rotationabout longitudinal axis A of cavity 111, and/or may be constrained fromlongitudinal movement along longitudinal axis A. Limited or no relativemovement between liquid delivery device 200 and body 110 facilitatesaccurate and repeatable detection of plunger 205 by sensors of sensorcarriage 140, and provides a predictable line of sight for the sensorsof sensor carriage 140.

In some example embodiments, sensor carriage 140 includes one or moresensor components configured to detect a condition of liquid deliverydevice 200 (e.g. as the sensor carriage moves between the first positionand the second position). Sensor carriage 140 may include components ofa plunger detection sensor, such as a reflective optical sensor or atransmissive optical sensor, and/or a position sensor, such as a loadsensor, linear potentiometer, linear encoder, rotary encoder, magneticpotentiometer, or membrane potentiometer, for example, configured todetect information that can be used to evaluate a condition of liquiddelivery device 200.

Referring now to FIG. 2, a cross-sectional view of liquid deliverysystem 10 is shown, including cap device 100 retained on liquid deliverydevice 200. Delivery end 202 and at least a portion of reservoir 201 ofliquid delivery device 200 are positioned within cavity 111 of capdevice 110. Front wall 112 includes engagement features configured toalign and/or engage delivery end 202. For example, front wall 112includes a tapered or chamfered wall portion 112 c that may directdelivery end 202 towards a centered location within cavity 111.Alternatively or additionally, engagement features 112 c interact with acomplementary surface of delivery end 202 to frictionally retaindelivery end 202. For example, wall portion 112 c may include one ormore ribs, detents, etc. to retain liquid delivery device 200 in a fixedposition within cavity 111.

Body 110 may include one or more features that orient and align liquiddelivery device 200 relative to body 110 (e.g. as the liquid deliverydevice 200 is inserted into cavity 111). For example, interior surfaces153 of track 150 and/or side walls 113 may include a tapered portion 153a proximate opening 114 such that a leading portion of track 150 iswider than an interior portion of track 150. Tapered portion 153 a mayfacilitate manual insertion of liquid delivery device 200 into cavity111 by directing liquid delivery device 200 towards a central locationwithin body 110. In some embodiments, tapered portion 153 a may guidecentral longitudinal axis B of liquid delivery device 200 into alignmentwith central longitudinal axis A of cavity 111. Alternatively oradditionally, track 150 and/or side walls 113 may include one or morerotational alignment features 153 b (FIG. 1) that guide liquid deliverydevice 200 into one or more predetermined angular orientations. In thisway, features of liquid delivery device 200 may be guided towards apredetermined angular position relative to cap device 100 and itssensors, such as sensors located on sensor carriage 140.

Referring now to FIGS. 3 and 4, an example sensor carriage 140 is shownthat is movable within body 110 of cap device 100. FIG. 3 shows across-sectional view of sensor carriage 140 within cap device 100, andFIG. 4 shows a perspective view of sensor carriage 140. Sensor carriage140 includes one or more sensor components configured to detect acondition of liquid delivery device 200, such as a position of a plungerwithin liquid delivery device 200. For example, sensor carriage 140includes a sensor 142 that outputs a sensor signal representative of acharacteristic of liquid delivery device 200. The output signal fromsensor 142 may vary depending on a physical characteristic of liquiddelivery device 200 encountered by sensor 142, and thus the outputsignal may differ at different positions along a length of liquiddelivery device 200. For example, as sensor carriage 140 moves relativeto liquid delivery device 200, a change in the output signal of sensor142 may be evaluated to determine a leading end of reservoir 201 (e.g.at delivery end 202), a leading end of plunger 205, a trailing end ofplunger 205, and/or other attributes of liquid delivery device 200. Achange in position detected between a series of doses, such as a changein position of plunger 205 before and after a dose has been delivered,may be used to evaluate a volume of a dose delivered by liquid deliverydevice 200, a remaining total volume of liquid within reservoir 201, aremaining number of doses within reservoir 201, a remaining durationuntil reservoir 201 is emptied, a time of the previous dose (e.g. a timethe cap device 100 was replaced on liquid delivery device 200), anelapsed time since the last dose (e.g. an elapsed time since cap device100 was replaced on liquid delivery device 200), and/or otherinformation related to liquid delivery device 200. Alternatively oradditionally, the relative positions of one or more of these detectedcharacteristics, or a distance between one or more of these detectedcharacteristics, may be used to evaluate dosage information related toliquid delivery device 200.

In an example embodiment, sensor 142 includes an emitter 142 a and areceiver 142 b, such as an optical emitter 142 a and optical emitter 142b. Optical emitter 142 a emits radiation that can be detected by opticalreceiver 142 b, and in some embodiments may include an LED or laserdiode. Sensor 142 may output a sensor signal related to the amount ofradiation received by optical receiver 142 b (e.g. an amount ofradiation received from optical emitter 142 a). The sensor signal maythus depend on the features of liquid delivery device 200 present inpath 142 c between optical emitter 142 a and optical received 142 b. Theamount of radiation received by optical receiver may thus be relativelylower when a plunger or other solid structure is present in path 142 c,and may be relatively higher when only transparent walls of a reservoirand its liquid contents are present in path 142 c, for example.

Emitter 142 a and receiver 142 b may be arranged in alignment with oneanother such that an optical path 142 c between emitter 142 a andreceiver 142 b extends perpendicular (e.g. substantially perpendicular,within 10° of exactly perpendicular) to the central longitudinal axis Aof cavity 111. In some embodiments, emitter 142 a is configured togenerate a narrow beam with limited spread outside of optical path 142c, such as by an emitter 142 a that emits a narrow beam and/or by acollimating structure configured to focus the output of emitter 142 aalong path 142 c. In various example embodiments, radiation emitted byemitter 142 a may be within visible and/or invisible wavelengths.

In some example embodiments, sensor 142 may be a reflective sensor thatdetects reflected light. Reflective sensor 142 may detect a colortransition indicative of plunger 205, such as transition from arelatively higher transparency and/or light color of liquid and/orreservoir 201 to the relatively lower transparency and/or dark color ofplunger 205 (e.g. red, orange, black, etc.).

Sensor carriage 140 may include multiple sensors, such as first andsecond optical sensors 142, 143 (FIG. 4). First optical sensor 142includes first emitter 142 a and first receiver 142 b, and secondoptical sensor 143 includes second emitter 143 a and second receiver 143b. First emitter 142 a may be aligned with first receiver 142 b andsecond emitter 143 a aligned with second receiver 143 b (e.g. such thatfirst receiver 142 b receives radiation primarily or exclusively fromfirst emitter 142 a and second receiver 143 b receives radiationprimarily or exclusively from second emitter 143 a). For example, firstemitter 142 a and second receiver 143 b, and second emitter 143 a andfirst receiver 142 b, are not in alignment and do not define an opticalpath perpendicular to the longitudinal axis of cavity 111. In an exampleembodiment, first and second emitters 142 a, 142 b, and first and secondreceivers 143 a, 143 b, are spaced 90° from each other around aperimeter of sensor carriage 140. Accordingly, first sensor 142 andsecond sensor 143 may define first and second paths 142 c, 143 coriented perpendicular to one another. In some embodiments, first path142 c and/or second path 143 c do not intersect with a centrallongitudinal axis (A) of cavity 111 or a central longitudinal axis (B)of liquid delivery device 200. First and/or second paths 142 c, 143 cthat do not intersect the central axis may facilitate detection oftrailing surface 205 b of plunger 205 by avoiding obstruction by rod214.

In various example embodiment, the relative locations of sensors 142 and143 may be selected to promote an appropriate line of sight (e.g.through liquid delivery device 200) by at least one of sensor 142 orsensor 143. The relative locations of sensors 142, 143 may be selectedbased on the features of liquid delivery device 200, such as thelocations of ribs, indicia, and other obstructions that could affectreliable detection of features of liquid delivery device 200, such asplunger 205 or delivery end 202. In some example embodiments, first andsecond paths 142 c, 143 c may form an angle between 15° and 90°, 30° and75°, or about 60°. Alternatively or additionally, first and secondsensors 142, 143 may be spaced along sensor carriage 140 in alongitudinal direction.

The paths of sensors 142, 143, may be angled relative to centrallongitudinal axes (A), (B) of cavity 111 and liquid delivery device 200.Angled sensor paths may facilitate detection of a plunger at a locationwithin an opaque region of liquid delivery device 200, such as duringinitial usage of liquid delivery device 200 while reservoir 201 remainsfull or nearly full. For example, angled sensor paths may allowdetection of the plunger without sensor carriage 140 itself traveling toa longitudinal position of plunger 205. In this way, sensors 142 maydetect characteristics of liquid delivery device 200 along a lengthgreater than a length that sensor carriage 140 travels along liquiddelivery device 200 between the first and second positions. Sensors 142may be configured to detect a magnitude of radiation reflected onleading surface 205 a of plunger 205. In various example embodiments,plunger 205 may be detected by angled sensor paths 142 d, 143 d, untilbetween about 10 units and 360 units, 20 units and 40 units, or about 30units have been dispensed from liquid delivery device 200, for example.

In some embodiments in which multiple optical sensors 142, 143 arepresent, distinct wavelengths may be emitted by each emitter 142 a, 143a, and receivers 142 b, 143 b may likewise be wavelength-specific, forexample, by including a bandpass filter. Alternatively or additionally,each sensor may emit and detect pulses of radiation in distinct timeperiods of a cycle (e.g. using time-division multiplexing). In someembodiments, sampling rates may be greater than 100 Hz, greater than1000 Hz, or higher.

Alternatively or additionally to sensors 142, 143, sensor carriage 140may include a position sensor 145 configured to output a sensor signalindicative of a position or distance. In an example embodiment, capdevice 100 includes a position sensor 145 that outputs a sensor signalindicative of a position of the sensor carriage and/or distance thesensor carriage traveled between a first position and a second position(e.g. as sensor carriage 140 moves along liquid delivery device 200 orbetween subsequent doses of liquid delivery device 200). In an exampleembodiment, position sensor 145 includes a linear potentiometer. Aresistive element 145 a is located at least partially along a length ofcavity 111, such as side wall 113 of body 110 or track 150. A wiper 145b is located on sensor carriage 140. Wiper 145 b may be biased towardsresistive element 145 a by an elastic element 145 c, such as a springarm or spring (FIG. 3) to promote continuous contact between resistiveelement 145 a and wiper 145 b. In some embodiments, the elastic element145 c provides a relatively low bias such that wiper 145 b remains incontact with resistive element 145 a while frictional resistance or wearof resistive element 145 a is reduced.

Sensor 145 may output a sensor signal (e.g a voltage) that variesdepending on the position of wiper 145 b along resistive element 145 a(e.g. and a position of sensor carriage 140 along cavity 111). Forexample, a particular voltage may be associated with a particularlocation along resistive element 145 a, and the voltage may beconsistent and repeatable each time wiper 145 b travels along resistiveelement 145 a. Sensor 145 may have a unique signature of voltage outputsfor each location of wiper 145 b, and can be calibrated to achievehighly precise and repeatable measurements. In some example embodiments,the resolution of sensor 145 may be between 1 μm and 30 μm, 2 μm and 15μm, 3 μm and 10 μm, or about 6 μm, and the resolution of liquid deliverydevice 200 may be about 130 μm. The resolution of sensor 145 of capdevice 100 may thus be between about 10 to 20 times the resolution ofliquid delivery device 200. Such resolutions of sensor 145 facilitate ahighly accurate determination of a position of plunger 205, with a levelof error contributed by the sensor that is an order of magnitude smallerthan variation in dose delivery by liquid delivery device 200, forexample.

In some embodiments, the precision and repeatability of sensor 145 maybe further enhanced by accounting for variation that may occur due toambient temperature changes. For example, cap device 100 may include atemperature sensor 129 (FIG. 1) that detects a temperature and outputs atemperature signal to processor 125. Processor 125 may account for achange in temperature when evaluating sensor signals received fromsensor 145 based on a predetermined relationship between temperature andsensor signals from sensors 142, 143, 145, etc.

Alternatively or additionally to a linear potentiometer, position sensor145 may include one or more other sensor types that provide anindication of position that can be correlated with an sensor signaloutput by sensor 142. For example, position sensor 145 may include alinear encoder, rotary encoder, magnetic potentiometer, membranepotentiometer, load cell, etc., for example.

In an example embodiment, processor 125 is configured to evaluate sensorsignals from sensors 142 and/or 143, such as a variation in sensorsignals indicative of the plunger, and to determine a correspondingposition based on the sensor signal from sensor 145. In someembodiments, the corresponding position may be stored and compared to acorresponding position of plunger 205 during a subsequent measurement. Achange in position may then be evaluated to determine the volume of thepreviously delivered dose (e.g. by evaluating the distance traveled byplunger 205). In some example embodiments, only a change in position ofplunger 205 is evaluated, and the position of plunger 205 relative toother components of liquid delivery device 200 and/or cap device 100 isnot evaluated.

Alternatively or additionally, the position of plunger 205 relative to afeature of liquid delivery device 200 and/or cap device may beevaluated. For example, processor may be configured to detect a sensorsignal output from sensors 142, 143 indicative of a leading end ofreservoir 201, and to determine a corresponding position based on theoutput signal from sensor 145. The relative positions of such featuresmay be evaluated to determine a distance between the leading end ofreservoir 201 and plunger 205, which in turn may facilitate calculationof a remaining total volume of liquid within reservoir 201, a remainingnumber of doses within reservoir 201, a remaining duration untilreservoir 201 is emptied, and/or other information related to liquiddelivery device 200.

Sensor carriage 140 may be electrically connected with processor 125 tofacilitate electrical communication of sensor signals. In someembodiments, a flexible electrical connector 147 provides electricalconnection at least partially between sensor carriage 140 and circuitboard 127 that supports processor 125. Flexible electrical connector mayinclude conductive electrical structures on a thin, flexible substrate.For example, the flexible electrical connector may include one or morelayers of PEEK, polyester, or polyamide having printed or laminatedelectrical structures. The flexible electrical connector thus may have athin profile that facilitates bending to a small radius of curvature.The flexible electrical connector may bend and flex while the sensorcarriage 140 travels along track 150, while maintaining electricalconnection with circuit board 127 and/or processor 125.

Alternatively or additionally, track 150 may include one or moreelectrical conductors that provide electrical communication betweensensor carriage 140 and circuit board 127 while sensor carriage 140travels along track 150. For example, sensor carriage 140 may have afixed electrical contact biased towards sliding engagement with acomplementary electrically conductive surface of track 150.

In some embodiments, sensor carriage 140 is not in continuous electricalconnection with circuit board 127 and/or processor 125. For example,sensor carriage 140 may operate to detect a condition of liquid deliverydevice 200 while not in electrical communication with circuit board 127and/or processor 125. Sensor carriage 140 may include a power sourcethat can deliver power to one or more sensors carried by sensor carriage140, and a sensor carriage memory to store sensor signal information.The sensor carriage 130 may store sensor information collected as ittravels between the first and second positions, and may be brought intoelectrical communication with circuit board 127 and/or processor 125when stopped at the first and/or second positions to upload thecollected information to memory 124.

Still referring to FIGS. 3 and 4, sensor carriage 140 includesengagement features configured to interact with track 150 and/or liquiddelivery device 200. In some optional embodiments, arms 146 of sensorcarriage 140 may guide sensor carriage 140 along slots 151. Arms 146extend at least partially into slots 151 so that sensor carriage 146 islimited to movement in a path directed by slots 151, and rotation ofsensor carriage 140 is prevented. Slots 151 may include a substantiallystraight portion parallel to central longitudinal axis A of cavity 111.Alternatively or additionally, slots 151 may include curved or helicalportions that cause sensor carriage 140 and/or track 150 to rotaterelative to one another and/or other components of cap device 140 assensor carriage 140 travels along cavity 111.

Referring now to FIGS. 5A, 5B, and 5C, sensor carriage 140 includes oneor more engagement features configured to interact with liquid deliverydevice 200. For example, sensor carriage 140 includes arms 146 that canbe pushed by liquid delivery device 200 to move sensor carriage 140.When liquid delivery device 100 is inserted into cavity 111,interference between arms 146 and liquid delivery device 200 causessensor carriage 140 to move with liquid delivery device 200 towardsfront wall 112 of body 110. Arms 146 may subsequently be moved out ofengagement with liquid delivery device 200 (e.g. by retracting,releasing, rotating, etc.) to release sensor carriage 140 to returntowards opening 114 of cavity 111 while liquid delivery device 200remains in a fixed position relative to cavity 111 of cap device 100. Insome embodiments, spring 160 may be compressed when liquid deliverydevice 200 is fully inserted into cavity 110, and spring 160 may returnsensor carriage 140 towards opening 114 when arms 146 are released fromengagement with liquid delivery device 200.

Referring to FIG. 5A, in an example embodiment, sensor carriage includesfour arms 146 radially spaced around a circumference of sensor carriage140. Arms 146 are movably between an extended position in which arms 146extend into a bore 148 defined by sensor carriage 140 (e.g. extendinginwardly away from an interior wall of sensor carriage 140), and aretracted position. For example, track 150 includes a major diameter (D)between opposing interior surfaces 153, and a minor diameter (d) betweenopposing arms 146 in the extended position. Major diameter (D) may beslightly larger than an outer diameter of liquid delivery device 200such that sensor carriage 140 can travel along the liquid deliverydevice 200. Minor diameter (d) may be slightly smaller than an outerdiameter of liquid delivery device 200, such that sensor carriage 140can be pushed by liquid delivery device 200 via extended arms 146. Whenarms 146 are in the retracted position, diameter (d) between opposingarms 146 may be greater than major diameter (D) such that sensorcarriage 140 can travel along the liquid delivery device 200 withoutinterference with arms 146.

Referring to FIGS. 5B and 5C, cap device 100 is engageable with liquiddelivery device 200 by insertion of delivery end 202 through opening 114of body 110 and into cavity 111. As liquid delivery device 200 isinserted through opening 114, delivery end 202 encounters engagementfeatures of sensor carriage 140, such as arms 146 in an extendedposition. As shown in FIG. 5C, relative movement between cap device 100and liquid delivery device 200 (e.g. as cap device 100 and liquiddelivery device 200 are brought together) results in liquid deliverydevice 200 pushing sensor carriage 140 into cavity 111. For example,liquid delivery device 200 pushes sensor carriage 140 along track 150from a position proximate opening 114 to a position proximate front wall112, compressing spring 160.

Body 110 and liquid delivery device 200 may include one or more featuresthat orient and align liquid delivery device 200 to body 110. In anexample embodiment, at least a portion of liquid delivery device 200includes a non-circular and/or asymmetric cross-section that can beaccommodated in cavity 111 in a discrete number of orientations. Liquiddelivery device 200 includes a non-circular body portion 207 having agenerally square or rectangular cross-section such that liquid deliverydevice 200 is position able within cavity 111 in one of fourorientations. In other example embodiments, non-circular body portion207 may have a triangular, pentagonal, polygonal, or other shape.Alternatively or additionally, liquid delivery device 200 may includeone or more protrusions or recesses that interact with complementaryrecesses or protrusions of cap device 100 to dictate a predeterminedangular orientation between liquid delivery device 200 and cap device100 when engaged. The cross-sectional shape, protrusions, and/orrecesses may promote a predetermined angular orientation duringengagement, and maintain the predetermined angular orientation while capdevice 100 is engaged with liquid delivery device 200. The locations andrelative angular orientations of sensors 142, 143 in cap device 100 maybe selected to facilitate a predetermined path between sensor emittersand receivers (e.g. that reduces obstruction by ribs, indicia, or otherfeatures of liquid delivery device 200) based on the predeterminedangular orientation of liquid delivery device 200.

Track 150 and/or side walls 113 of cap device 100 may include one ormore rotational alignment features 153 b that guide liquid deliverydevice 200 towards the predetermined angular orientation. For example,features of liquid delivery device 200 may be guided towards thepredetermined angular position relative to cap device 100 and itssensors. Alignment features 153 b may interact with body portion 207after delivery end 202 has been inserted into cavity 111, and may guideliquid delivery device 200 into the predetermined angular orientation.

Referring now to FIGS. 6A, 6B, and 6C, movable sensor carriage 140 isshown in a first position (FIG. 6A), intermediate position (FIG. 6B),and second position (FIG. 6C). Sensor carriage 140 is movable betweenthe first, intermediate, and second positions while liquid deliverydevice 200 remains fixedly positioned relative to body 110 and cavity111. Movement of sensor carriage 140 between the first and secondpositions facilitates detection of characteristics of liquid deliverydevice 200 at multiple locations of liquid delivery device 200. Sensor142 may generate output signals continuously or at a relatively highfrequency (e.g. between 0.1 and 100 kHz, between 5 and 50 kHz, or about30 kHz) while sensor carriage 140 moves between the first and secondpositions. In some embodiments, operation of sensor 142 as sensorcarriage 140 travels between the first and second positions can bedescribed as generating a scan of a portion of liquid delivery device200, and the output signals from sensors 142 (e.g. alone or inconjunction with one or more sensors, such as sensor 145) can beevaluated to determine a position of plunger 205 within reservoir 201, achange in position of plunger 205 within reservoir 201, and/or otherconditions of liquid delivery device 200.

In the first position shown in FIG. 6A, sensor carriage 140 is locatedproximate front wall 112 of body 110. Sensor carriage 140 may be broughtinto the first position by the operation of inserting liquid deliverydevice 200 within cavity 111. In an example embodiment, spring 160 is ina compressed configuration when sensor carriage 140 is in the firstposition. Movement of sensor carriage 140 from the first position may beinitiated by the release of sensor carriage 140 and/or spring 160. Forexample, one or more engagement features of sensor carriage 140, such asarms 146, may interact with liquid delivery device 200. Upon reachingthe first position, the engagement features may be moved or releasedsuch that sensor carriage 140 and liquid delivery device 200 are nolonger maintained in a fixed position relative to one another. Sensorcarriage 140 may be released upon reaching the first position withoutadditional manual operation. In other example embodiments, sensorcarriage 140 may be retained in the first position until released bymanual operation (e.g. by manual movement or release of arms 146).

Sensor carriage 140 is movable from the first position towards thesecond position by spring 160. Spring 160 is biased towards anuncompressed or less compressed configuration in which sensor carriage140 is located in a second position proximate opening 114 of cavity 111.Spring 160 may be characterized by a spring constant that providessufficient force to overcome frictional resistance between resistiveelement 145 a and wiper 145 b, and between sensor carriage 140, track150, and/or other components of cap device 100, so that sensor carriage140 is movable between the first and second positions in a smooth andcontrolled manner (e.g. with predictable velocity and acceleration). Forexample, a minimum force of spring 160 (e.g. when extended by sensorcarriage 140 in a second position) may be greater than 1N, greater than1.5N or about 2N. The force of spring 160 is sufficiently low tofacilitate robust retention of cap 100 on liquid delivery device 200.For example, a maximum force of spring 160 (e.g. when compressed bysensor carriage 140 in a first position) may be less than about 5N, lessthan about 4.5N, or about 4N, or lower.

Sensor 142 of sensor carriage 140 may output sensor signals as sensorcarriage 140 travels between the first and second positions along liquiddelivery device 200. In a first position shown in FIG. 6A, path 142 cbetween emitter 142 a and receiver 142 b intersects delivery end 202 ofliquid delivery device 200. The sensor signals may be evaluated (e.g. byprocessor 125) to detect the presence of a leading end of reservoir 201,such as a location immediately reward of tapered walls 204a. Forexample, a magnitude of radiation received by receiver 142 b mayincrease or step up between a location at which optical path 142 cpasses through tapered walls 204a and a location at which optical path142 c passes through walls 204b oriented substantially parallel to alongitudinal axis of reservoir 201. In some embodiments, a particularmagnitude of the sensor signal, or an increase in the magnitude of thesensor signal, may thus provide an indication of the leading end ofreservoir 201.

FIG. 6B shows sensor carriage 140 in an intermediate position betweenthe first and second positions. Optical path 142 c between emitter 142 aand receiver 142 b passes through an intermediate location of reservoir201. The walls 204b of reservoir 201, and the liquid within reservoir201 b, may provide relatively lower opacity to transmission of radiationbetween emitter 142 a and receiver 142 b, such that the sensor signalsare relatively higher in the intermediate position.

FIG. 6C shows sensor carriage 140 in a second position in which sensorcarriage 140 is located proximate opening 114 of cavity 111. In thesecond position, sensor carriage 140 has traveled beyond leading surface205 a of plunger 205 such that path 142 c intersects plunger 205. Thepresence of leading surface 205 a may be detected by a change in thesensor signal at the location path 142 c encounters leading surface 205a. For example, a magnitude of radiation received by receiver 142 b maybe reduced or stepped down due to the presence of plunger 205 in path142 c.

Sensor 142 may continue to detect characteristics of liquid deliverydevice 200 after traveling beyond leading surface 205 a of plunger 205.For example, a trailing surface 205 b may be detected based on a changein the sensor output at a location that trailing surface 205 bintersects path 142 c. For example, a magnitude of radiation received byreceive 142 b may be increased or stepped up due to the absence ofplunger 204 intersecting path 142 c. The length of plunger 205 betweenleading surface 205 a and trailing surface 205 b is fixed and thuseither the leading surface 205 a or the trailing surface 205 b may beused to evaluate a position of plunger 205. Detecting both the leadingand trailing surfaces 205 a, 205 b of plunger 205 may improve theaccuracy in evaluating plunger 205. For example, the position of plunger205 may be accurately located even if a leading or trailing surface 205a, 205 b, is obstructed by another feature of liquid delivery device200, such as a rib, indicia, etc.

The position of plunger 205 or a change in position of plunger 205 maybe evaluated in conjunction with sensor signal output by position sensor145. In an exemplary embodiment, sensor signals generated by positionsensor 145 vary in a predictable manner as sensor carriage 140 movesbetween the first position and the second position. For example, asensor signal of position sensor 145 for a particular location may beassociated with a sensor signal from sensor 142 at the particularlocation. A change in position of plunger 205 before and after a dosehas been delivered may be detected, and the volume of the delivered dosecalculated based on the change in position. Alternatively oradditionally, a distance between locations associated with variousoutput signals from sensor 142 may be evaluated, such as a distancebetween a leading end of reservoir 201 and a leading surface 205 ofplunger 205, and the remaining volume with reservoir 201 calculatedbased on the distance.

Referring now to FIGS. 7A and 7B, engagement features of sensor carriage140 are shown in an extended or engaged configuration (FIG. 7A) and in aretracted or disengaged configuration (FIG. 7B). In an exampleembodiment, sensor carriage 140 includes a rotatable ring 147 associatedwith arms 146. Ring 147 may be rotatable to cause arms 146 to movebetween the extended and retracted configurations. For example, arms 146and ring 147 may include complementary features that interact when ring147 is rotated relative to other components of sensor carriage 140. Insome example embodiments, arm 146 and ring 147 include complementaryteeth 146 a, 147 a that interact similar to a rack and pinion. Rotationof ring 147 in a first direction moves arms 146 from the extendedconfiguration to the retracted configuration, and rotation of ring 147in a second direction moves arms 146 from the retracted configuration tothe extended configuration. In this way, arms 146 are movable between anengaged configuration that facilitates interference with liquid deliverydevice 200 (e.g. during insertion of liquid delivery device 200 intocavity 111) and a retracted configuration that avoids interference withliquid delivery device 200 (e.g. such that sensor carriage 140 maytravel along a portion of liquid delivery device 200 during a plungerdetection operation).

Cap device 100 may include features that cause arms 146 to move betweenthe extended and retracted positions when sensor carriage 140 reachesthe first and second positions, respectively. For example, in someembodiments, arms 146 are configured to move between extended andretracted positions without additional manual operation beyond insertionof liquid delivery device 200 into cavity 111. Body 110 may include arecess 115 having an angled or ramped surface. Ring 147 includes aprotrusion 147 b engageable with the ramped surface of recess 115. Whenthe protrusion 147 b encounters the ramped surface (e.g. due to theforce of inserting liquid delivery device 200 into cavity 111), ring 147is caused to rotate in a first direction relative to other portions ofsensor carriage 140. Arms 146 in turn are moved to the retractedposition shown in FIG. 7B. Movement of arms 146 to the retractedposition (e.g. when cap device 100 is engaged on liquid delivery device200 and sensor carriage 140 is in the first position proximate frontwall 112) may release sensor carriage 140 such that spring 160 causessensor carriage 140 to travel along liquid delivery device 200 from thefirst position to the second position.

Slots 151 of track 150 may include widened end regions 152 (FIG. 3) thatfacilitate or direct movement of arms 146 between extended and retractedpositions. For example, widened end regions may provide additionalclearance for rotation of arms 146. Alternatively or additionally,widened end regions 152 may include a ramped surface or other featureengageable with sensor carriage 140 that causes arms 146 to move betweenengaged and retracted configurations. Slots 151 may be configured toprevent or limit rotation or disengagement of arms 146 while the sensorcarriage 140 moves between first and second positions.

In some exemplary embodiments, body 110 may include one or more featuresthat cause ring 147 to rotate in a second direction relative to otherportions of sensor carriage 140 when sensor carriage 140 reaches asecond position proximate opening 114 (e.g. reaches the second positiondue to movement caused by spring 160). Referring now to FIG. 8, capdevice 100 may include a spring 117 that interacts with ring 147 whensensor carriage 140 is in the second position. Spring 117 is biased tocause ring 147 to rotate in the second direction and, in turn, causearms 146 to return to the extended configuration. The presence of liquiddelivery device 200 within cavity 111 prevents arms 146 from moving tothe extended position, and thus ring 147 may be forced to rotate byspring 117 only upon removal of liquid delivery device 200.

In an example embodiment, rotation of ring 147 and/or movement ofengagement features such as arms 146 between extended and retractedpositions may occur without manual operation beyond insertion andremoval of liquid delivery device 200. For example, insertion of liquiddelivery device 200 moves sensor carriage 140 into the first positionand subsequently releases sensor carriage 140 to scan liquid deliverydevice 200 while traveling from the first position to a second position.Removal of liquid delivery device 200 from cavity 111 allows arms 146 toreturn to an extended position in which cap device 100 is ready to againreceive liquid delivery device 200. Accordingly, in various exampleembodiments, cap device 100 is configured to repeatedly and reliablyscan liquid delivery device 200 to determine the location of plunger205, and evaluate subsequent plunger positions to determine variouscharacteristics of liquid delivery device 200 and its use.

Referring now to FIGS. 9A and 9B, a partial perspective view and across-sectional view of an example liquid delivery device 200 are shown.Liquid delivery device 200 includes various features that may affect thesensor signal of a sensor, such as sensor 142. For example, liquiddelivery device 200 may include a region 208 having relatively higheropacity, ribs 209, indicia 210, and/or other features that allowrelatively lower transmission of radiation utilized by sensors 142, anda region 212 having relatively lower opacity. Such features may act asan obstruction, and/or result in a sensor signal that is similar to asensor signal generated when plunger 205 is encountered. Similarly,plunger 205 may include bumps or protrusions 211 on its leading surface.

In various exemplary embodiments, such features can be avoided and/oraccounted for by a predetermined angular orientation of cap device 100and liquid delivery device 200. As shown in FIG. 9B, liquid deliverydevice 200 includes paths (C), (D) through region 212 having relativelylower opacity. Alternatively or additionally, paths (C), (D) avoidintersection with one or more of region 208 having higher opacity, ribs209, and/or indicia 210. In an example embodiment, cap device 100 may beconfigured to orient liquid delivery device 200 such that a sensor pathof at least one sensor, such as path 142 c of sensor 142, is alignedsimilar to paths (C) or (D) to avoid intersection with such features.For example, sensor carriage 140 having two sensors 142, 143 offset fromone another (e.g. in the configuration shown in FIG. 4) facilitatesalignment of at least one sensor path through region 212. The sensorsignals output by sensors 142, 143 can be processed to reliablydistinguish plunger 205 from one or more other features of liquiddelivery device 200. Alternatively or additionally, sensor signalsoutput by sensors 142, 143 can be processed to account for the presenceof bumps or protrusions 211 (e.g. by evaluating a series of sensorsignals from each of sensors 142, 143). Accordingly, reliable andrepeatable detection of plunger 205 may be achieved by accounting forone or more other features of liquid delivery device 200, and/ormaintaining liquid delivery device 200 in a fixed longitudinal andangular position relative to cap device 100 during operation.

Referring now to FIGS. 10-11, an example liquid delivery system 50 isshown that can be used to store and deliver a liquid. Liquid deliverysystem 50 includes cap device 700 and liquid delivery device 900. Liquiddelivery device 900 includes a reservoir 901, delivery end 902, and aplunger 905 that can be operated to deliver a dose of the liquid withinreservoir 901 through delivery end 902. Cap device 700 is positionableover delivery end 902 of liquid delivery device 900 for storage ofliquid delivery device 900 between uses. In an example embodiment, capdevice 700 includes one or more sensors that may be configured to detecta condition of liquid delivery device 900, such as a position of itsplunger, and one or more output devices, such as a display,communication system, etc., configured to output information related tothe condition of liquid delivery device 900. In some exampleembodiments, liquid delivery system 50 includes features andcharacteristics similar to features and characteristics of liquiddelivery system 10 described above with reference to FIGS. 1 through 9.

Cap device 700 may include one or more sensors configured to detect acondition of liquid delivery device 900. In an example embodiment, capdevice 700 includes sensors that output sensor signals that may beevaluated to detect a plunger, a position of the plunger, a change inposition of the plunger between successive engagements with cap device700 (e.g. a change in position after delivery of a dose), and/or otherconditions of liquid delivery device 900. The position of the plunger,and/or a change in the position of the plunger, may be used to monitor avolume of a dose delivered by liquid delivery device 900, a remainingtotal volume of liquid within reservoir 902, a remaining number of doseswithin reservoir 902, a remaining duration until reservoir 902 isemptied, and/or other information related to liquid delivery device 900.

In some embodiments, cap device 700 includes a sensor carriage 740 thatis movable within body 710 (e.g. movable within cavity 711). Sensorcarriage 740 is configured to travel along at least a portion of liquiddelivery device 900 within cavity 711, and cavity 711 is sized toaccommodate the dimensions of liquid delivery device 900 and a path forsensor carriage 740. Sensor carriage 740 facilitates detection ofcharacteristics of liquid delivery device 900 by carrying one or moresensors along liquid delivery device between a first position and asecond position. Sensor carriage 740 is optionally movable between thefirst position and the second position relative to the cavity 711 whileliquid delivery device 900 remains in a fixed position relative to thecavity 711 (e.g. the sensor carriage 740 is movable while the liquiddelivery device 900 is fixedly engaged with cap device 700).

In an example embodiment, cap device 700 includes a spring 760configured to move sensor carriage 740 from a first position to a secondposition. For example, spring 760 may be manually compressed to movesensor carriage 740 to a first position proximate the front wall 712 ofbody 710, such as by insertion of liquid delivery device 900 into cavity711, and may be biased to return sensor carriage to a second positionproximate opening 714 of body 710 when released.

Sensor carriage 740 includes one or more sensor components configured todetect a condition of liquid delivery device 900 as the sensor carriagemoves between a first position and a second position. In various exampleembodiments, sensor carriage 740 includes components of a plunger sensorconfigured to detect information that can be used to evaluate acondition of liquid delivery device 900. Alternatively, sensor carriage740 may include only components of a position sensor (e.g. and not aplunger sensor). In some embodiments, one or more optical sensors 744may be fixedly positioned on body 710 of cap device 700.

Referring now to FIGS. 10A-10D, sensor carriage 740 includes one or moreengagement features configured to interact with liquid delivery device900. For example, sensor carriage 740 includes arms 746 that can bepushed by liquid delivery device 900 to move sensor carriage 740. Whenliquid delivery device 900 is inserted into cavity 711, interferencebetween arms 746 and liquid delivery device 900 causes sensor carriage740 to move with liquid delivery device 900 towards front wall 712 ofbody 710. Arms 746 may subsequently be moved out of engagement withliquid delivery device 900 to release sensor carriage 740 to returntowards opening 714 of cavity 711 while liquid delivery device 900remains in a fixed position relative to cavity 711 of cap device 700.For example, arms 746 may be flexible arms that may be movable betweenan engaged and disengaged configurations by interaction with one or moreother components of sensor carriage 740 and/or cap 700. In someembodiments, spring 760 may be compressed when liquid delivery device900 is fully inserted into cavity 710, and spring 760 may return sensorcarriage 740 towards opening 714 when arms 746 are released fromengagement with liquid delivery device 900.

In an example embodiment, sensor carriage 740 includes two arms 746spaced around a circumference of sensor carriage 740. Arms 746 aremovably between an extended position in which arms 746 extend into abore 748 defined by sensor carriage 740 (e.g. extending inwardly awayfrom an interior wall of sensor carriage 740), and a retracted position.Arms 746 may be movable relative to one or more components of sensorcarriage 740, such as a sensor carriage ring 749 a including camsurfaces 749 b. In a first relative position (FIGS. 10A-10B), arms 746are maintained in a flexed or engaged configuration by cam surfaces 749b. The arms 746 extend into bore 748 and are positioned to interferewith a liquid delivery device inserted into cap device 700. In a secondrelative position (FIGS. 10C-10D), arms 746 are out of contact with camsurfaces 749 b and are in an unflexed or disengaged configuration (e.g.arms 746 are not forced into the engaged position by cam surfaces 749b). Arms 746 are positioned such that sensor carriage 740 can moverelative to bore 748 and/or liquid delivery device 900 positioned withinbore 748 without interference that prevents movement.

Relative movement between arms 746 and cam surface 749 b may occur dueto interaction between sensor carriage 740 and one or more features ofcap device 700. For example, body 711 may include one or more ribs 718that prevent further longitudinal movement of sensor carriage ring 749 aduring insertion of liquid delivery device 900. Continued movement ofarms 746 may move arms 746 out of contact with cam surface 749 b suchthat the arms can flex to a retracted or disengaged configuration (FIGS.10C-10D). When the sensor carriage 740 is returned to a positionproximate opening 714 (e.g. by spring 760), ribs 719 may prevent furtherlongitudinal movement of sensor carriage ring 749 a while spring 760continues to push arms 746. Arms 746 may thus be forced into contactwith cam surface 749 b and moved to the extended or engagedconfiguration.

Referring to FIGS. 11A-F, cap device 700 is engageable with liquiddelivery device 900 by insertion of delivery end 902 through opening 714of body 710 and into cavity 711. As liquid delivery device 900 isinserted through opening 714 (FIG. 11A), delivery end 902 encountersengagement features of sensor carriage 740, such as arms 746 in anextended position. Relative movement between cap device 700 and liquiddelivery device 900 (e.g. as cap device 700 and liquid delivery device900 are brought together) results in liquid delivery device 900 pushingsensor carriage 740 into cavity 711 (FIG. 11B). When sensor carriage 740reaches a position proximate front wall 712 of body 710, for example,longitudinal movement of sensor carriage ring 749 a is stopped by ribs718 while arms 746 may move relative to sensor carriage ring 749 a (e.g.by force from insertion of liquid delivery device 900). Such relativemovement results in arms 746 moving out of contact with cam surface 749b and into a disengaged configuration (FIG. 11C). Movement of arms 746to the disengaged configuration moves arms 746, and sensor carriage 740,out of interference with liquid delivery device 900 such that the sensorcarriage may be moved by spring 760 (e.g. towards opening 714) (FIG.11D). When sensor carriage 740 reaches a position proximate opening 714of body 710, for example, movement of sensor carriage ring 749 a isstopped by ribs 719 while arms 746 may move relative to sensor carriagering 749 a (e.g. by force from spring 760) (FIG. 11E). Such relativemovement results in arms 746 moving into contact with cam surface 749 band into a flexed or engaged configuration (FIG. 11F). With the sensorcarriage 740 located proximate opening 714, and arms 746 in the engagedconfiguration, liquid delivery device 900 may again be received and theprocess repeated, for example.

Referring now to FIG. 12, an example liquid delivery system 20 is shownthat can be used to store and deliver a liquid. Liquid delivery system20 includes cap device 300 and liquid delivery device 400. Liquiddelivery device 400 includes a reservoir 401, delivery end 402, and aplunger 405 that can be operated to deliver a dose of the liquid withinreservoir 401 through delivery end 402. Cap device 300 is positionableover delivery end 402 of liquid delivery device 400 for storage ofliquid delivery device 400 between uses. In an example embodiment, capdevice 300 includes one or more sensors, including a linear encoder. Thecap device is configured to detect a condition of liquid delivery device400, such as a position of its plunger, and one or more output devices,such as a display, communication system, etc., configured to outputinformation related to the condition of liquid delivery device 400. Insome example embodiments, liquid delivery system 20 includes featuresand characteristics similar to features and characteristics of liquiddelivery system 10 described above with reference to FIGS. 1 through 11.

Liquid delivery device 400 may be configured to deliver a measured doseof a liquid to a subject for the treatment of a medical condition. Forexample, liquid delivery device 400 may be a pen injector for deliveringa liquid, such as insulin, to manage diabetes. In an example embodiment,delivery end 402 of liquid delivery device 400 includes a septum 403 andan injection needle 404. A desired dosage may be measured by operationof dial 406 (e.g. by manually rotating dial 406), and operating liquiddelivery device 400 to advance plunger 405. Advancement of plunger 405via rod 414 pushes the measured dosage of liquid from reservoir 401,through delivery end 402, and into the subject. In an exampleembodiment, advancement of plunger 405 a particular distance results ina corresponding volume of liquid dispensed from liquid delivery device400.

Cap device 300 may include one or more sensors configured to detect acondition of liquid delivery device 400. In an example embodiment, capdevice 300 includes sensors that output sensor signals that may beevaluated to detect a plunger, a position of the plunger, a change inposition of the plunger between successive engagements with cap device300 (e.g. a change in position after delivery of a dose), and/or otherconditions of liquid delivery device 400. The position of the plunger,and/or a change in the position of the plunger, may be used to monitor avolume of a dose delivered by liquid delivery device 400, a remainingtotal volume of liquid within reservoir 402, a remaining number of doseswithin reservoir 402, a remaining duration until reservoir 402 isemptied, and/or other information related to liquid delivery device 400.

Cap device 300 optionally includes user inputs 322 that facilitate userinteraction with cap device 100. In an example embodiment, user inputs322 include first and second buttons that may be operated to control capdevice 300. For example, user inputs 322 may be operated by a user toactivate cap device 300 and/or select information for display by display321. Alternatively or additionally, user inputs 322 may be operated toreset settings and/or memory of cap device 300, such as when cap device300 is engaged with a new liquid delivery device 400. In some exampleembodiments, cap device 300 does not include manually-operable userinputs. Cap device 300 that does not include buttons or other userinputs may improve ease of operability and promote the perception of afully automated cap device 300.

Cap device 300 may communicate with one or more other components of aliquid delivery system to deliver and/or receive information related toa condition of cap device 100 and/or liquid delivery device 400. Forexample, cap device 300 includes a communication device 323 configuredto communicate with one or more components remote from cap device 300.Communication device 323 may include a wireless communication printedcircuit assembly configured for wireless communication, such as viashort-wavelength UHF radio frequency, RF communication, WI-FI,BLUETOOTH, ZIGBEE, etc. Alternatively or additionally, communicationdevice 323 may include an electrical port for wired communication withanother electronic device. In various example embodiments, communicationdevice 323 is configured for two-way communication, such as two-waycommunication with a mobile device having software configured to deliverand receive communications with cap device 300. Alternatively, capdevice 300 may be configured for one-way communication, such as only toupload information to the mobile device, or only to receive informationfrom the mobile device.

Communication device 323 may be configured to communicate with anelectronic device configured with diabetes management software. Forexample, communication device 323 may transmit information related toliquid delivery device 400 that may be further processed by theelectronic device. In this way, cap device 300 may facilitate remotereview of information collected by its sensors by a remote user orhealthcare provider, provide alerts related to liquid delivery system400 by the electronic device (e.g. related to a scheduled time for aninjection, a nearly empty liquid delivery device, etc.), and/orfacilitate additional processing of the information collected by capdevice 300.

In some embodiments, cap device 300 optionally includes a sensorcarriage 340 that is movable within body 310 (e.g. movable within cavity311). Sensor carriage 340 is configured to travel along at least aportion of liquid delivery device 400 within cavity 311, and cavity 311is sized to accommodate the dimensions of liquid delivery device 400 anda path for sensor carriage 340. Sensor carriage 340 facilitatesdetection of characteristics of liquid delivery device 400 by carryingone or more sensors along liquid delivery device between a firstposition and a second position. Sensor carriage 340 is optionallymovable between the first position and the second position relative tothe cavity 311 while liquid delivery device 400 remains in a fixedposition relative to the cavity 311 (e.g. the sensor carriage 340 ismovable while the liquid delivery device 400 is fixedly engaged with capdevice 300).

Cap device 300 may include a track 350. Sensor carriage 340 may travelalong track 350, and track 350 may include one or more features thatguide and/or limit the movement of sensor carriage 340. In an exampleembodiment, cap device 300 includes a spring 360 configured to movesensor carriage 340 from a first position to a second position. Forexample, spring 360 may be manually compressed to move sensor carriage340 to a first position proximate the front wall 312 of body 310, suchas by insertion of liquid delivery device 400 into cavity 311, and maybe biased to return sensor carriage to a second position proximateopening 314 of body 310 when released.

Sensor carriage 340 includes one or more sensor components configured todetect a condition of liquid delivery device 400 as the sensor carriagemoves between a first position and a second position. In various exampleembodiments, sensor carriage 340 includes components of a plungersensor, such as an optical sensor, and a position sensor, such as linearencoder, configured to detect information that can be used to evaluate acondition of liquid delivery device 400. Alternatively, sensor carriage340 may include only components of a position sensor (e.g. and not aplunger sensor). In some embodiments, one or more optical sensors 344may be fixedly positioned on body 310 of cap device 300.

In some embodiments, sensor carriage 340 has a sensor 342 (e.g. aplunger sensor) that includes an emitter 342 a and a receiver 342 b,such as an optical emitter 342 a and optical emitter 342 b. Opticalemitter 342 a emits radiation that can be detected by optical receiver342 b, and in some embodiments may include an LED or laser diode.Optical receiver 342 b may output a signal related to the amount ofradiation received from optical emitter 342 a, which may be dependent onthe portion of liquid delivery device 400 present in path 342 c betweenoptical emitter 342 a and optical received 342 b. The amount ofradiation received by optical receiver may thus be relatively lower whenpath 342 c intersects plunger or other solid structure, and may berelatively higher when path 342 c intersects transparent walls of areservoir and its liquid contents.

Alternatively or additionally to sensor 342, sensor carriage 340 mayinclude a position sensor 345 configured to output a sensor signalindicative of a position or distance. In an example embodiment, capdevice 300 includes a position sensor 345 that outputs a sensor signalindicative of a position of sensor carriage 340 and/or distance sensorcarriage 340 traveled between a first position and a second position(e.g. as sensor carriage 340 moves along liquid delivery device 400 orbetween subsequent doses of liquid delivery device 400). In an exampleembodiment, position sensor 345 includes a linear encoder, such as areflective linear encoder or a transmissive linear encoder. An encodercodestrip 345 a is located at least partially along a length of cavity311, such as side wall 313 of body 310 or track 350. An encoder 345 b,such as an optical encoder, is located on sensor carriage 340. In someexample embodiments, encoder 345 b may be positioned in close proximityto codestrip 345 a but out of contact with codestrip 345 a.

Linear encoder 345 may output a sensor signal (e.g. a count) that variesdepending on the position of encoder 345 b along codestrip 345 a (e.g.and a position of sensor carriage 340 along cavity 311). In variousexample embodiments, codestrip 345 a includes an optical pattern, suchas a series of alternating dark and white lines. The linear encoder 345may output a sensor signal indicative of a position of encoder 345 balong codestrip 345 a. For example, a particular count may be associatedwith a particular location along codestrip 345 a, and the count may beconsistent and repeatable each time encoder 345 b travels alongcodestrip 345 a.

The resolution of the encoder may be enhanced to a resolution finer thanthe thickness of the alternating lines of codestrip 345 a by detecting atransition at the leading edge of each line and/or velocity-basedinterpolation techniques. In various example embodiments, linear encoder345 may provide a highly accurate and reliable measurement having aresolution of less than 25 μm, less than 15 μm, less than 10 μm, betweenabout 5 μm and 10 μm, or about 7.5 μm. The resolution of liquid deliverydevice 400 may be about 130 μm. The resolution of sensor 345 of capdevice 300 may thus be between about 10 to 20 times the resolution ofliquid delivery device 400. Such resolutions of sensor 345 facilitates ahighly accurate determination of a position of plunger 405 with asignificantly smaller error than the variation in dose delivery byliquid delivery device 400. In various example embodiments, highresolution may be achieved with little or no calibration of sensor 345during assembly of cap device 300.

In an example embodiment, cap device 300 includes a processor configuredto evaluate sensor signals from sensors 342 and/or 344, such as avariation in sensor signals indicative of the plunger, and to determinea corresponding position based on the sensor signal from sensor 345. Insome embodiments, the corresponding position may be stored and comparedto a corresponding position of the plunger during a subsequentmeasurement. A change in position may be evaluated to determine thevolume of the previously delivered dose (e.g. by evaluating the distancetraveled by the plunger). In some example embodiments, only a change inposition of the plunger is evaluated, and the position of the plungerrelative to other components of liquid delivery device 400 and/or capdevice 300 is not evaluated.

Alternatively or additionally, the position of the plunger relative to afeature of liquid delivery device 400 and/or cap device 300 may beevaluated. For example, the processor may be configured to detect anoutput signal from one or more sensors 342 and/or 344 indicative of aleading end of reservoir 404, and to determine a corresponding positionbased on the output signal from sensor 345. The relative positions ofsuch features may be evaluated to determine a distance between theleading end of reservoir 404 and plunger 405, which in turn facilitatecalculation of a remaining total volume of liquid within reservoir 402,a remaining number of doses within reservoir 402, a remaining durationuntil reservoir 402 is emptied, and/or other information related toliquid delivery device 400.

Encoder 345 b is out of contact during operation of sensor 345 such thatencoder 345 b is separated from codestrip 345 a by a space. Encoder 345b thus does not create frictional resistance by contact with codestrip345 a, and frictional wear does not occur. Encoder 345 b can repeatedlytravel along codestrip 345 a without wearing or otherwise affectingcodestrip 345 a. in some example embodiments, an optional spring 348 maybe included to provide controlled drag against the motion of sensorcarriage 340 propelled by spring 360. Controlled movement of sensorcarriage 340 may be facilitated without causing frictional engagement orwear on components of sensors 342, 344, or 345, for example.

Alternatively or in addition to sensor 342, a sensor 344 fixedlypositioned on body 310 of cap device 300 may be used to detect theplunger and/or other features of liquid delivery device 400. Sensors 344may output sensor signals as liquid delivery device 400 is inserted intocavity 311 and brought into engagement with cap device 300. Spring 360may promote controlled manual insertion of liquid delivery device 400into cavity 311 of cap device 300.

Referring now to FIG. 13, an example liquid delivery system 30 is shownthat includes a rotary encoder position sensor. Liquid delivery system30 includes cap device 500 that is positionable over a delivery end of aliquid delivery device for storage of the liquid delivery device betweenuses. In an example embodiment, cap device 500 includes one or moresensors configured to detect a condition of the liquid delivery device,such as a position of its plunger, and one or more output devices, suchas a display, communication system, etc., configured to outputinformation related to the condition of the liquid delivery device. Insome example embodiments, liquid delivery system 30 includes featuressimilar to features of liquid delivery systems 10 and 20 described abovewith reference to FIGS. 1 through 12.

Cap device 500 may include one or more sensors configured to detect acondition of the liquid delivery device. In an example embodiment, capdevice 500 includes sensors that output sensor signals that may beevaluated to detect a plunger, a position of the plunger, a change inposition of the plunger between successive engagements with cap device500 (e.g. a change in position after delivery of a dose), and/or otherconditions of the liquid delivery device. The position of the plunger,and/or a change in the position of the plunger, may be used to monitor avolume of a dose delivered by the liquid delivery device, a remainingtotal volume of liquid, a remaining number of doses, a remainingduration until the liquid delivery device is emptied, and/or otherinformation related to the liquid delivery device.

Cap device 500 optionally includes user inputs 522 that facilitate userinteraction with cap device 500. In an example embodiment, user inputs522 include first and second buttons that may be operated to control capdevice 500. For example, user inputs 522 may be operated by a user toactivate cap device 500 and/or select information for display by display521. Alternatively or additionally, user inputs 522 may be operated toreset settings and/or memory of cap device 500, such as when cap device500 is engaged with a new liquid delivery device. In some exampleembodiments, cap device 500 does not include manually-operable userinputs. Cap device 500 that does not include buttons or other userinputs may improve ease of operability and promote the perception of afully automated cap device 500.

Cap device 500 may communicate with one or more other components of aliquid delivery system to deliver and/or receive information related toa condition of cap device 500 and/or a liquid delivery device. Forexample, cap device 500 includes a communication device 523 configuredto communicate with one or more components remote from cap device 500.Communication device 523 may include a wireless communication printedcircuit assembly configured for wireless communication, such as viashort-wavelength UHF radio frequency, RF communication, WI-FI,BLUETOOTH, ZIGBEE, etc. Alternatively or additionally, communicationdevice 523 may include an electrical port for wired communication withanother electronic device. In various example embodiments, communicationdevice 523 is configured for two-way communication, such as two-waycommunication with a mobile device having software configured to deliverand receive communications with cap device 500. Alternatively, capdevice 500 may be configured for one-way communication, such as only toupload information to the mobile device, or only to receive informationfrom the mobile device.

Communication device 523 may be configured to communicate with anelectronic device configured with diabetes management software. Forexample, communication device 523 may transmit information related to aliquid delivery device that may be further processed by the electronicdevice. In this way, cap device 500 may facilitate remote review ofinformation collected by its sensors by a remote user or healthcareprovider, provide alerts related to the liquid delivery system by theelectronic device (e.g. related to a scheduled time for an injection, anearly empty liquid delivery device, etc.), and/or facilitate additionalprocessing of the information collected by cap device 500.

In some embodiments, cap device 500 optionally includes carriage 540configured to receive at least a portion of a liquid delivery device.For example, carriage 540 may be configured to receive a delivery end ofa liquid delivery device, and/or move together with the liquid deliverydevice as the liquid delivery device is engaged with cap device 500. Capdevice includes a track 550 that carriage 540 is movable along (e.g.that guides and or limits carriage 540 as it travels within cavity 511).

In an example embodiment, cap device 500 includes a spring 560configured to move carriage 540 from a first position to a secondposition. For example, spring 560 may be manually compressed whencarriage 540 is moved towards front wall 512 of cavity 511, such as byinsertion of a liquid delivery device 500 into cavity 511. Spring 560may be biased to return carriage 540 to a second position proximateopening 514 of body 510 when released (e.g. when the liquid deliverydevice is removed from engagement with cap device 500). In an exampleembodiment, spring 560 is seated around spring hat 586.

Cap device 500 includes one or more sensor components configured todetect a condition of the liquid delivery device as the liquid deliverydevice is brought into engagement with cap device 500. In an exampleembodiment, cap device 500 includes a plunger sensor and/or a rotaryencoder, configured to detect information that can be used to evaluate acondition of a liquid delivery device. For example, cap device 500includes one or more sensors 544 fixedly positioned proximate opening514 of cavity 511. Sensors 544 may include an emitter 542 a and areceiver 542 b, such as an optical emitter 542 a and optical emitter 542b. Optical emitter 542 a emits radiation that can be detected by opticalreceiver 542 b, and in some embodiments may include an LED or laserdiode. Optical receiver 542 b may output a signal related to the amountof radiation received from optical emitter 542 a, which may be dependenton the portion of the liquid delivery device present in path 542 cbetween optical emitter 542 a and optical receiver 542 b. The amount ofradiation received by optical receiver may thus be relatively lower whena plunger or other solid structure is present in path 542 c, and may berelatively higher when transparent walls of a reservoir and its liquidcontents are present in path 542 c.

Alternatively or additionally to sensor 544, cap device 500 may includecomponents of a position sensor configured to output a sensor signalindicative of a position or distance. In an example embodiment, capdevice 500 includes a rotary encoder 570 that outputs a sensor signalindicative of a position of carriage 540 and/or distance carriage 540traveled between a first position and a second position (e.g. ascarriage 540 is pushed along cavity 511 during engagement of cap device500 with a liquid delivery device).

Cap device 500 includes a track 550 having a helical slot 551. An end oftrack 550 is retained between track ring 585 and helical track base 584such that track 550 is rotatable relative to carriage 540, body 510,and/or other components of cap device 500. Movement of carriage 540along cavity 511 causes rotation of track 550 (e.g. rotation relative tocarriage 540, body 510, and/or other components of cap device 500.

In an example embodiment, position sensor 545 includes an encodercodewheel 545 a, and an encoder 545 b, such as an optical encoder.Encoder 545 b may be located in close proximity to codewheel 545 a, butout of contact with codewheel 545 a. The rotation of track 550 istranslated to codewheel 545 a and/or encoder 545 b. The correspondingrotation is detected by encoder 545 b. The rotary encoder 545 maygenerate a sensor signal (e.g. a count) that varies depending on therelative rotation of codewheel 545 a and encoder 545 b. In an exampleembodiment, codewheel 545 a includes an optical pattern, such as aseries of alternating dark and white lines. The rotary encoder 545 mayoutput a sensor signal indicative of the rotation detected by encoder545 b. For example, a particular count may be associated with aparticular rotation of codewheel 545 a, and thus a particular rotationof track 550, and the count may be consistent and repeatable each timecarriage 540 travels along track 550.

The resolution of the encoder can be enhanced to a finer resolution thanthe thickness of the alternating lines of codewheel 545 a by detecting atransition at the leading edge of each line and/or velocity-basedinterpolation. In various example embodiments, linear encoder 345 mayprovide a highly accurate and reliable measurement having a resolutionof less than 25 μm, less than 15 μm, less than 10 μm, between about 5 μmand 10 μm, or about 7.5 μm.

The resolution of rotary encoder 345 may be further enhanced by a geartrain 581 between track 550 and codewheel 345 a. For example, gear trainmay include gears 581 a, 581 b, 581 c, 581 d, 581 e, that provide a gearratio between 2 and 100, 4 and 50, 8 and 25, or of about 16. Gears 581a, 581 c, 581 e, may be rotatable on main shaft 582 supported by abearing 583, for example, and gears 581 b, 581 d, rotatable on gear post589. Accordingly, in some embodiments, each rotation of track 150 mayproduce multiple rotations of codewheel 545 a.

In some embodiments, encoder 545 b may be out of contact with codewheel545 a during operation of rotary encoder 545 such that encoder 545 b isseparated from codewheel 545 a by a space. Encoder 545 b thus does notcreate frictional resistance by contact with codewheel 545 a, andfrictional wear of codewheel 545 a due to contact by encoder 545 b doesnot occur. Encoder 345 b can repeatedly detect codewheel 345 a withoutwearing or otherwise affecting codewheel 345 a.

Various example cap devices described herein facilitate effective,repeatable techniques of evaluating a condition of a liquid deliverydevice. Referring to FIG. 14, a flow diagram of an example method 800 ofevaluating the condition of a liquid device is shown. Method 800includes operation 802 of receiving at least a portion of a liquiddelivery device within a cavity of a cap device. In various exampleembodiments, the liquid delivery device may have features andcharacteristics similar to liquid delivery devices 200, 400, 600,described herein, and may be a pen-injector device for administering adose of insulin.

Operation 802 may include aligning the liquid delivery device with thecavity of the cap device, such as aligning a central longitudinal axisof the liquid delivery device with a central longitudinal axis of thecavity of the cap device. Alternatively or additionally, operation 40may include aligning the liquid delivery device into one or morediscrete alignment positions with the cap device. For example, liquiddelivery device and/or cap device may have an asymmetrical featureand/or non-circular shape that facilitates receiving the liquid deliverydevice in one or more discrete positions selected based on locations ofone or more sensors within the cap device. Operation 802 includingaligning the liquid delivery device with the cap device in a particularorientation facilitates desired interaction between one or more sensorsof the cap device and the liquid delivery device by reducinginterference or obstruction by ribs, indicia, opaque regions, and/orother features.

In an example embodiment, operation 802 of receiving the liquid deliverydevice with the cavity of the cap device may include fixedly engagingthe cap device with the liquid delivery device. For example, afteroperation 802, relative motion between the liquid delivery device andthe cap device may be limited such that the liquid delivery device isnot rotatable within the cavity and/or the liquid delivery device is notmovable longitudinally within the cavity.

Method 800 may include operation 804 of releasing a sensor carriageincluding one or more sensors. When the sensor carriage is released, thesensor carriage may move from a first position to the second positionwhile the liquid delivery device remains in a fixed position within thecavity. For example, the sensor carriage may move from a first positionproximate a front wall that partially defines the cavity to a secondposition proximate an opening of the cavity. One or more sensor signalslocated on the sensor carriage operate while the sensor carriage movesbetween the first and second positions to output sensor signalsindicative of one or more features of the liquid delivery device.

In some example embodiments, operation 804 of releasing the sensorcarriage may be initiated without additional manual operation. Forexample, when the liquid delivery device is engaged with the cap device,the sensor carriage may be released without manual operation. One ormore engagement features of the sensor carriage that interact withliquid delivery device may be moved or released such that the sensorcarriage and liquid delivery device are not restricted to a fixedposition relative to one another.

Method 800 may further include operation 806 of evaluating an output ofthe one or more sensors indicative of the presence of a feature of theliquid delivery device. For example, the cap device may include aprocessor configured to evaluate sensor signals from one or more of thesensors, such as a variation in sensor signals indicative of theplunger, and to determine a corresponding position. In some embodiments,operation 806 may include storing the corresponding position andcomparing the corresponding position during subsequent capping events.Evaluating the sensor signals may including evaluating a change inposition to determine the volume of the previous dose delivery (e.g. byevaluating the distance traveled by plunger 205), a remaining volumewithin the liquid delivery device, or other characteristics of theliquid delivery device.

In some embodiments, method 800 may include operation 808 of displayingan output related to the position of the plunger. For example, operation808 may include displaying the previously delivered dose. Alternativelyor additionally, operation 808 may include displaying dose informationrelated to a remaining total volume of liquid within the reservoir ofthe liquid delivery device, a remaining number of doses within thereservoir of the liquid delivery device, a remaining duration until thereservoir of the liquid delivery device is emptied, a time of theprevious dose (e.g. a time of operation 802 of receiving the liquiddelivery device within the cavity), an elapsed time since the last dose(e.g. an elapsed time since operation 802 of receiving the liquiddelivery device within the cavity), and/or other information related tothe liquid delivery device.

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of thedisclosed technology or of what may be claimed, but rather asdescriptions of features that may be specific to particular embodimentsof particular disclosed technologies. Certain features that aredescribed in this specification in the context of separate embodimentscan also be implemented in combination in a single embodiment in part orin whole. Conversely, various features that are described in the contextof a single embodiment can also be implemented in multiple embodimentsseparately or in any suitable subcombination. Moreover, althoughfeatures may be described herein as acting in certain combinationsand/or initially claimed as such, one or more features from a claimedcombination can in some cases be excised from the combination, and theclaimed combination may be directed to a subcombination or variation ofa subcombination. Similarly, while operations may be described in aparticular order, this should not be understood as requiring that suchoperations be performed in the particular order or in sequential order,or that all operations be performed, to achieve desirable results.Particular embodiments of the subject matter have been described. Otherembodiments are within the scope of the following claims.

1-23. (canceled)
 24. A liquid delivery system cap device, the cap devicecomprising: a body defining a cavity configured to receive at least aportion of a liquid delivery device; a first sensor configured to outputa first sensor signal indicative of a plunger of the liquid deliverydevice; a second sensor configured to output a second sensor signalindicative of a position; and a processor configured to detect a plungerof the liquid delivery device based on a variation in the sensor signalof the first sensor, and to determine a corresponding position based ona sensor signal output by the second sensor; wherein the second sensorcomprises a linear encoder including a code strip and an encoder. 25.The cap device of claim 24, wherein the linear encoder is at least oneof a reflective linear encoder and a transmissive linear encoder. 26.The cap device of claim 24, wherein the linear encoder is located on asensor carriage movable within the cavity of the body between a firstposition and a second position.
 27. The cap device of claim 26, whereinthe first sensor is fixed relative to the body and is located on thesensor carriage and movable between the first position and the secondposition.
 28. The cap device of claim 26, wherein the cap deviceincludes a first spring biased to move the sensor carriage between thefirst position and the second position.
 29. The cap device of claim 28,wherein the sensor carriage comprises a second spring in frictionalengagement with the body while the sensor carriage moves between thefirst position and the second position.
 30. The cap device of claim 26,wherein the linear encoder is separated from the code strip by a spacewhen the sensor carriage is movable between the first position and thesecond position.
 31. A liquid delivery system cap device, the cap devicecomprising: a body defining a cavity configured to receive at least aportion of a liquid delivery device; a first sensor configured to outputa first sensor signal indicative of a plunger of the liquid deliverydevice; a second sensor configured to output a second sensor signalindicative of a position; and a processor configured to detect a plungerof the liquid delivery device based on a variation in the sensor signalof the first sensor, and to determine a corresponding position based ona sensor signal output by the second sensor; wherein the second sensorcomprises a rotary encoder including a codewheel and an encoder.
 32. Thecap device of claim 31, comprising a track and a carriage movablebetween a first position and a second position along the track, whereinthe carriage is configured to receive a delivery end of a liquiddelivery device.
 33. The cap device of claim 32, wherein the trackcomprises a helical slot, and the track is rotatable by movement of thecarriage between the first position and a second position along thehelical slot.
 34. The cap device of claim 33, wherein rotation of thetrack causes rotation of the codewheel.
 35. The cap device of claim 34,further comprising a gear train, wherein rotation of the track istranslated to the codewheel via the gear train.
 36. The cap device ofclaim 32, wherein the carriage does not include a sensor or sensorcomponent.
 37. The cap device of claim 32, wherein the first sensor isfixedly positioned relative to the body of the cap device.
 38. The capdevice of claim 32, wherein the first sensor is located on the carriagemovable between a first position and a second position.
 39. A method ofevaluating the condition of a liquid delivery device, comprising:receiving at least a portion of a liquid delivery device within a cavityof a cap device; generating by a first sensor a first sensor signalindicative of a feature of a liquid delivery device; generating by asecond sensor a second sensor signal output indicative of a positionassociated with the first sensor signal output; and evaluating the firstsensor signal output and the sensor signal output to determine aposition of the feature of the liquid delivery device.
 40. The method ofclaim 39, wherein the second sensor comprises a linear encoder includinga code strip and an encoder, and generating the second sensor signaloutput comprises moving the encoder along the code strip.
 41. The methodof claim 39, wherein the second sensor comprises a rotary encoderincluding a code wheel and an encoder, and generating the second sensorsignal output comprises relative rotation between the codewheel and theencoder.
 42. The method of claim 39, wherein the feature is a plunger ofthe liquid delivery device, and the method further comprising displayingan output related to the position of the plunger.
 43. The method ofclaim 42, wherein the output is the volume of a previous dose deliveredfrom the liquid delivery device.